Cooling tower integrated inlet louver fill

ABSTRACT

A fill sheet arrangement in a direct heat exchange section of a cooling tower is provided. Each fill sheet includes ridges, grooves, separators, and an air inlet louver zone itself having ridges, grooves and separators, that improve the performance of the fill sheet arrangement when installed as a direct heat exchange section of a cooling tower. The air inlet louver zone between adjacent fill sheets to improve the air flow capabilities and performance of the direct heat exchange section by limiting the evaporative liquid from leaving the fill sheet.

BACKGROUND OF THE INVENTION

The present invention relates to air inlet louver zone of heat and mass transfer media, or fill sheet arrangement within the direct heat exchange portion of a cooling tower. More particularly, the present invention relates to inlet louver zone attached to a fill sheet that is used in a direct heat exchange unit, which could be a cooling tower.

The heat and mass transfer media, or fill sheet arrangement, is generally vertically oriented with an evaporative liquid, usually water, coursing over the material, usually flowing downwardly, with an air stream directed usually transversely but potentially concurrent or cross current through the spaced fill sheet direct cooling section. The air interacts with the evaporative liquid for heat and mass transfer.

The integrated air inlet louver zone is attached to an edge of fill sheet, is a part of fill sheet, directs airstream to fill, and limits evaporative fluid from leaving the fill sheet beyond the fill sheet edge.

SUMMARY OF THE INVENTION

The invention made improvements to the air inlet louver zone included in the fill sheet near the first side edge of the fill sheet arrangement. Each fill sheet includes an air inlet louver zone comprised of a plurality of gradually raised surfaces that lead to form the raised ridges of each fill sheet.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings,

FIG. 1 is a side view of a first fill sheet in accordance with an embodiment of the present invention;

FIG. 2 is a partial view of a first inlet louver zone showing a male indexer and adjacent raised surfaces in accordance with an embodiment of the present invention;

FIG. 3 is a partial view of a first inlet louver zone showing a male indexer and cutouts in adjacent raised surfaces in accordance with an embodiment of the present invention;

FIG. 4 is a perspective side view of a second fill sheet in accordance with an embodiment of the present invention;

FIG. 5 is a partial view of a second fill sheet showing second inlet louver zone in accordance with an embodiment of the present invention;

FIGS. 6A and 6B are schematic views of a portion of a first and second inlet louver zone showing a male indexer in accordance with an embodiment of the present invention;

FIGS. 7A, 7B and 7C are schematic views of a portion of a first and second inlet louver zone showing a male separator in accordance with an embodiment of the present invention;

DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to FIG. 1 of the drawings, a first fill sheet is shown at 10 and a first inlet louver zone is shown at 15. First fill sheet 10 is shown to be of a generally rectangular and generally planar structure; however, it should be understood that based on design of installation needs first fill sheet 10 may be of a square or trapezoidal structure as well. First fill sheet 10 is seen to comprise a top edge 11, bottom edge 12, first side edge 18, and second side edge 14. Cooling air typically enters from the direction of first side edge 18 and travels and exits towards the general direction of second side edge 14. Included in first fill sheet 10 is first inlet louver zone 15 extending from first inlet edge 18 to transition edge 13. It is noted that transition edge 13 may be straight or curved. First inlet louver zone 15 is shown to be of a generally rectangular and generally planar structure; however, it should be understood that based on design of installation needs first inlet louver zone 15 may be of a square or trapezoidal structure as well. First inlet louver zone 15 extends from first side edge 18 to transition edge 13 and from top edge 11 to bottom edge 12. Generally, when installed in a direct heat exchange unit, possibly as a component of a cooling tower, evaporative liquid, usually water, flows downwardly onto top edge 11 and across first fill sheet 10, and exits bottom edge 12. First side edge 18 is typically an air inlet edge wherein air is forced or drawn cross-current to the evaporative liquid downward flow to exit from second side edge 14. Such combination of evaporative liquid generally flowing down and cross-current air flow acts to remove heat from the evaporative liquid by both a heat and mass transfer operation. It should be understood that air flow may be somewhat counter current or con-concurrent with the evaporative liquid downward flow, depending on the design of the direct heat exchange unit.

Each first fill sheet 10 including first inlet louver zone 15 are usually comprised of polyvinyl chloride, polypropylene, or any other plastic sheet formed in a press, vacuum forming, or molding operation.

First fill sheet 10 is seen to comprise of plurality of first fill sheet ridges 34 on the rear surface of first fill sheet 10 extending from first transition edge 13 to second side edge 14. Alternating with first fill sheet ridges 34 are first fill sheet grooves 35.

First inlet louver zone 15 is also seen to comprise of plurality of first ridges 20 extending length wise from first side edge 18 to first transition edge 13 matching the shapes of a plurality of first sheet ridge 34. Alternating with first ridge 20 are first grooves 21, which also extend lengthwise across first inlet louver zone 15 from first side edge 18 to first transition edge at an inclined angle.

Referring now to FIG. 2, first fill sheet 10 is shown with first inlet louver zone 15 is also seen to comprise a first male indexer 30, first male separators 31, and first recessed ridges 32.

First male indexer 30 extends upwardly from the surface of first inlet louver zone 15. As to be further explained, first male indexer 30 is typically located on first groove 21 on the rear surface of first inlet louver zone 15.

First male separator 31 extends upwardly from the surface of first inlet louver zone 15. As to be further explained, the extended surface of first male separator 30 is typically flush with first inlet louver zone ridge 20, and the center of first male separator 30 is typically located on first ridge 20 on the rear surface of first inlet louver zone 15.

First recessed ridge 32 extends upwardly from the surface of first inlet louver zone 15 to slightly lower than first ridge 20. First ridge side wall 33 connects first groove 21 to first recessed ridge 32.

Referring now to FIG. 3, first fill sheet 10 is shown with first ridge 20 and first ridge cutout 36 on two adjacent first ridges 20 of first male indexer 30.

Referring now to FIG. 4, second fill sheet 40 is seen to be quite similar to first fill sheet 10 in that second fill sheet 40 also is a generally rectangular, generally planar structure, having top edge 41, bottom edge 42, first side edge 43 and second side edge 44.

Included in second fill sheet 40 is second inlet louver zone 50 extending from first inlet edge 43 to transition edge 51 and from top edge 41 to bottom edge 42. It is noted that transition edge 51 may be straight or curved. Second inlet louver zone 50 is seen to be quite similar to first inlet louver zone 15 in that second inlet louver zone is shown to be of a generally rectangular and generally planar structure; however, it should be understood that based on design of installation needs second inlet louver zone 50 may be of a square or trapezoidal structure as well.

Second fill sheet 40 including second inlet louver zone 50 is again quite similar or identical to first fill sheet 10 there to in being comprised of polyvinyl chloride, polypropylene, or any other plastic sheet made in a pressing, vacuum forming, or molding operation.

Further, second fill sheet 40 is seen to comprise a series of second fill sheet ridges 45 on the front surface of second fill sheet 40 and alternating series of second fill sheet grooves 46 on the front surface of second fill sheet 40. Second fill sheet ridges 45 extend lengthwise from transition edge 51 to second side edge 44 and second fill sheet grooves 46 extend lengthwise from transition edge 51 to second side edge 44.

Second inlet zone 50 is seen to comprise a series of second inlet zone ridges 52 extending from first edge 43 and transition edge 51. Similarly, second inlet zone 50 is seen to comprise a series of second inlet zone groove 53 extending from first edge 43 and transition edge 51. Second inlet zone ridge 52 aligns with second fill sheet ridge 45 and second inlet zone groove 53 aligns with second fill sheet groove 46.

Referring now to FIG. 5, second fill sheet 40 has second inlet louver zone 50, which is also seen to comprise a second male indexer 55, first male separators 56, and second recessed ridges 57.

Second male indexer 55 extends upwardly from the surface of second inlet louver zone 50. As to be further explained, second male indexer 55 is typically located on second groove 53 on the front surface of second inlet louver zone 50.

Second male separator 56 extends upwardly from the surface of first second inlet louver zone 50. As to be further explained, the extended surface of second male separator 56 is typically flush with second inlet louver zone ridge 52, and the center of first male separator 56 is typically located on second ridge 52 on the front surface of second inlet louver zone 50.

Second recessed ridge 57 extends upwardly from the surface of second inlet louver zone 50 to slightly lower than second ridge 52. Second ridge side wall 58 connects second groove 53 to second recessed ridge 57.

In practice, a fill arrangement in a direct heat exchange unit would be comprised of two fill sheets located adjacent each other and repeated multiple times as needed to occupy the heat exchanger. Subsequently, two inlet louver zones included in the two fill sheets would also be located adjacent each other and repeat multiple times as needed.

Referring now to FIG. 6A, schematics are shown wherein a portion of first inlet louver zone 15 is seen to be adjacent a portion of second inlet louver zone 50. First fill sheet first male indexer 30 is seen to extend from first groove 21 on the rear surface of first fill sheet 10 toward second recessed ridge 57 on the front surface of second fill sheet 50. During the assembly process of stacking first fill sheet 10 adjacent to second fill sheet 40, as first male indexer 30 travel toward second inlet louver zone 50, second ridge side wall 58 guides first male indexer 30 toward second recessed ridge 57. FIG. 6b shows desired location of first inlet louver zone 15 with respect to second inlet louver zone 50 and first male indexer 30 contacting second recessed ridge 57. Air travels through a plurality of air paths 60 created by adjacent first inlet louver zone 15 and second inlet zone, but for those air paths that are partially blocked by first male indexer 30, first ridge cutout 36 allows 50 air to go around first male indexer 30 and behind first ridge 20.

Referring now to FIG. 7a , schematic shows the intended location of first inlet zone 15 location with respect to second inlet zone 50 wherein a portion of first inlet louver zone 15 is seen to be adjacent a portion of second inlet louver zone 50 and wherein first fill sheet first male separator 31 is seen to extend from first groove 21 to first ridge 20 on the rear face of first inlet louver zone 15 and wherein the rear face of first ridge 20 comes in contact with the front face of second groove 53 of second inlet louver zone 50. FIG. 7b is seen where a portion of second inlet louver zone 50 is located lower than the intended position with respect to first inlet louver zone 15 and the rear face of first ridge 20 misses the front face of second groove 53 but first male separator 31 abuts the front face of second groove 53. Similarly, FIG. 7c is seen where a portion of second inlet louver zone 50 is located higher than intended position with respect to first inlet louver zone 15 and the rear face of first ridge 20 misses the front face of second groove 53 but first male separator 31 abuts the front face of second groove 53. 

What is claimed is:
 1. An inlet louver zone for se in a direct heat exchanger, wherein a first inlet louver zone comprises a generally rectangular structure having a first side edge, a second side edge, a top edge, and a bottom edge, a front surface and a rear surface, and wherein a first fill sheet comprises a generally rectangular structure having a first side edge, a second side edge, a top edge, and a bottom edge, a front surface and a rear surface wherein a second side edge of the first inlet louver zone is attached to the first side edge of the first fill sheet, and wherein a second inlet louver zone comprises a generally rectangular structure having a first side edge, a second side edge, a top edge and a bottom edge, a front surface and a rear surface, and wherein a second fill sheet comprises a generally rectangular structure having a first side edge, a second side edge, a top edge, and a bottom edge, a front surface and a rear surface wherein a second side edge of the second inlet louver zone is attached to the first side edge of the second fill sheet, and the second inlet louver zone is adjacent the first inlet louver zone, the first inlet louver zone including a plurality of ridges and grooves, the second inlet louver zone including a plurality of ridges and grooves, wherein when the first inlet louver zone and the second inlet louver zone are adjacent in the direct heat exchanger, a ridge on the rear surface of the first inlet louver zone is adjacent a ridge on the front surface of the second inlet louver zone to form a contact surface, and a groove on the rear surface of the first fill sheet is adjacent a groove in the front surface of the second fill sheet to form major air path, wherein a ridge on the second inlet louver zone is slightly lowered to form a recessed ridge, the recessed ridge having sides that start from the groove of second inlet louver zone and end at the recessed ridge to form a guiding path, and a male indexer extends from a groove on the rear surface of the first inlet louver zone into the major air path and nests in the recessed ridge.
 2. The inlet louver zone of claim 1, wherein the male indexer has a shape that is an elongated circle or elliptical to minimize air pressure drop.
 3. The inlet louver zone of claim 1, wherein a plurality of male separators extending from the groove of first inlet louver zone to the ridge of first inlet louver zone contact the groove of second inlet louver zone.
 4. The inlet louver zone of claim 3, wherein the width of each male separator of the first inlet louver zone is greater than the minimum distance between two grooves of second inlet louver zone.
 5. The inlet louver zone of claim 1, wherein the male separator has two raised surfaces, wherein the raised surfaces have curved ridge cutouts for air to go around the male separator without incurring a significant pressure drop.
 6. The inlet louver zone of claim 1, wherein the male indexer extending from the groove on the rear surface of the first inlet louver zone limits the movement of the second inlet louver zone and second fill sheet relative to the first inlet zone in a perpendicular direction of the ridge in a plane of central surface.
 7. An inlet louver zone for use in a direct heat exchanger, wherein a first inlet louver zone comprises a generally rectangular structure on a first fill sheet, with the first inlet louver zone having a first side edge, a second side edge, a top edge, and a bottom edge, a front surface and a rear surface, and wherein a second inlet louver zone comprises a generally rectangular structure on a second fill sheet, with the second inlet louver zone having a first side edge, a second side edge, a top edge and a bottom edge, a front surface and a rear surface, and wherein the second inlet louver zone is adjacent the first inlet louver zone, the first inlet louver zone including a plurality of ridges and grooves, the second inlet louver zone including a plurality of ridges and grooves, wherein when the first inlet louver zone and the second inlet louver zone are adjacent n the direct heat exchanger, a ridge on the rear surface of the first inlet louver zone is adjacent a ridge on the front surface of the second inlet louver zone to form a contact surface, and a groove on the rear surface of the first fill sheet is adjacent a groove in the front surface of the second fill sheet to form a major air path, wherein a ridge on the second inlet louver zone is slightly lowered to form a recessed ridge, the recessed ridge having sides extending from the groove of second inlet louver zone to the recessed ridge to form a guiding path, and a male indexer extends from a groove on the rear surface of the first inlet louver zone into the major air path.
 8. The inlet louver zone of claim 7, wherein the male indexer has a shape that is an elongated circle or elliptical to minimize air pressure drop.
 9. The inlet louver zone of claim 7, wherein a plurality of male separators extending from the groove of first inlet louver zone to the ridge of first inlet louver zone contact the groove of second inlet louver zone.
 10. The inlet louver zone of claim 9, wherein the width of each male separator of the first inlet louver zone is greater than the minimum distance between two grooves of second inlet louver zone.
 11. The inlet louver zone of claim 7, wherein the male separator has two raised surfaces, wherein the raised surfaces have curved ridge cutouts for air to go around the male separator without incurring a significant pressure drop.
 12. The inlet louver zone from claim 7, Wherein the male indexer extending from the groove on the rear surface of the first inlet louver zone limits the movement of the second inlet louver zone and second fill sheet relative to the first inlet zone in a perpendicular direction of the ridge in a plane of central surface. 